batch- and loading systems with the batching master 110i/210i · intelligent batch...
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Intelligent Batch Solutions.........designed for you IB
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Batch- and loading systems with the Batching Master 110i/210i
Presentation Batching Master V08 © 2016 IBS BatchControl GmbH Page 1
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Batching Master 110i (intrinsically safe)
Batching Master 110 (non-Ex unit)
- Field housing, IP 65
For wall mounting
(240 x 240 x 120 mm)
- Local installation, direct
at the loading station
- Backlight optional
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- Panel mount
(144 x 144 x 130 mm)
- Front IP 65
- Backlight optional
Batching Master 210i (intrinsically safe)
Batching Master 210 (non-Ex unit)
Presentation Batching Master V08 © 2016 IBS BatchControl GmbH Page 3
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Loading system for road tankers
and railway tank wagons Batch system for basic products in
the pharmaceutical production
The Batching Master controls your batching process
at a filling station: in the production:
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Application pictures:
IBC filling: Truck loading:
Mobile filling system for IBC’s with
an Optimass 7300C flowmeter
Truck loading system for bio fuels
with a Promass 84F
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Indication in the field:
- pre-set value
- batched quantity
- actual flow rate, grand total
- temperature, density and
pressure optional
Safe operation in the field
The operator has all important
information for a safe batching
process locally at the filling
station.
In case of a failure, the operator is
able to stop the batch very quick
by the emergency stop switch of
the Batching Master.
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4
20
I [mA]
Start Batchedquantity [kg]
Batch completed
0510152025
4
20
I [mA]
Start Batchedquantity [kg]
Batch completed!
051015
Flow meters:
All types of flow meters can be connected to the Batching Master via single
pulses, double pulses or via a 4-20 mA signal.
Precise batch:
The batching valve can be controlled
by a 4-20 mA output signal which opens
with a soft start-ramp and which closes
at the end of the batch in 5 steps.
Due to these ramps it is possible to get
the highest batch accuracies.
No “pressure hammers” in high
flow rate systems:
They are eliminated because of the
soft-start ramp and the 5-step shut-
down ramp of the 4 - 20 mA signal
to the batching valve.
4-20 mA valve output
ramp for high quantities:
4-20 mA valve output ramp
for small quantities:
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Error messages in clear text
The Batching Master has many safety- and monitoring functions. In case of a
failure the batch will be stopped immediately. After the reset of the failure the
message, the batch can be continued via the start button.
Emergency stop switch
The Batching Master 110i has a proofed emergency stop switch at the front,
which can be delivered optional with a key for interlocking of the device.
When the emergency stop is pressed, then :
- the batch process will be stopped with a failure message
- the 4-20 mA valve output signal will be switched to 0 mA
- the digital outputs 1-3 will be deactivated
- one digital output give the message “emergency stop pressed”.
There is one digital input for an external emergency stop contact available.
Presentation Batching Master V08 © 2016 IBS BatchControl GmbH Page 8
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Low flow rate monitoring
If the flow rate during the batch falls below a programmed value, then the
batch process will be stopped after a programmed time. This function
prevents an uncontrolled filling during a failure in the measuring system.
Sensor break- and measuring range overrun monitoring
The Batching Master monitors the 4-20 mA input and the NAMUR contact
input circuit. In case of a sensor break or a measuring range overrun the
batch will be stopped with a failure message.
Error at the flow meter
The error output of the flow meter can be connected to a digital input of the
Batching Master. In case of a failure at the flow meter the batch process will
stopped with a failure message.
Presentation Batching Master V08 © 2016 IBS BatchControl GmbH Page 9
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Two release signals
These two custom specific release signals
work via digital inputs. If they are not
activated, then the batch will be stopped
with a failure message.
The texts of the messages can be changed
by the programming.
Terminal function:
The supervisory system is able to use the
Batching Master as a HMI (human machine
interface) to the operator in the field.
The supervisory system is able to show
question texts at the display of the device
and the user is able to make selections or
to enter information like order numbers or
access codes.
Presentation Batching Master V08 © 2016 IBS BatchControl GmbH Page 10
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PID controller functions
The Batching Master has two separate controller functions, they are working
parallel only during the batch. The output signals of the two controllers are
working in a min-selection at the 4-20 mA output to the batching valve.
Flow controller
Via the flow controller it’s possible to batch the product with a required
flowrate.
Override controller
The override controller is able to control a second physical value during the
batch, e.g. the temperature or the pressure of the product.
Presentation Batching Master V08 © 2016 IBS BatchControl GmbH Page 11
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Pressure keeping of liquefied Gas
Liquefied gas like LPG, Propane or Butane demonstrates out gassing effects
as soon as the pressure falls below the vaporization pressure of the gas.
These vapour locks would cause fail-measurements in the flow meter.
The override control function
of the Batching Master keeps
the pressure during the batch.
The 25-step linearization func-
tion of the Batching Master
delivers the right pressure set
point depending on the
temperature signal.
A parallel PID flow controller
function is also available.
Flow signal
Temperature
Pressure Ou
tpu
t sig
na
l to
th
e
ba
tch
ing
va
lve
Vapour pressure
curve Propan
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Manual filling/purge functions
For the emptying, cleaning or filling of the pipe system it could be
necessary to open the batching valve. This can be done by a digital
input, by the Modbus interface or by the function key F1. During this time
the flow rate signal will not be counted.
Automatic filling/purge functions
It is also possible to fill or purge the system automatically before each
batching process for a programmed time, or until a contact at a digital
input indicates liquid in the pipe.
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Complete batch systems:
IBS BatchControl offers complete batching
systems packages (turn key projects)
Consisting of: engineering support, control
panels, pumps, flow meters, valves, batch
controllers, Exi-interfaces, Exd-housings,
printers and loading software.
Batch systems for ultra pure water:
Used in the pharmaceutical and cosmetic
industries
The continuous water flow in a circulatory
system prevents the formation of germs.
The Batching Master close the circle valve
before the batch start. Different time
functions take care, that only the batched
quantity during the batch will be counted.
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Product way selection via the function keys F1 - F3
With this function 3 products can be batched with one flow meter. The
product way can be selected with the function keys before the start. The
question text and the product texts can be modified by the programming.
Presentation Batching Master V08 © 2016 IBS BatchControl GmbH Page 15
Pulse-
input
+15
- 16
4-20 mA
output
+ 29
- 30
+33 -34
Digital-
output 1
Digital-
output 3 Power
supply
+1 -2 +5 -6
24 VDC+24 V
+24 V
+ 31
- 32
Digital-
output 2
Batching Master 110
Product 1
Product 1
Product 1Batching
valve
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Flow conversion functions
for the calculation between mass, volume and
standard volume.
The flow input signal can be mass or volume.
The calculation can be done via the temperature,
pressure and density signal.
Calculation formulas:
- API 2540 / 2004 table for crude oil, refined- and
special products in metric units
- linear correction function
The base density at standard temperature can be
programmed or calculated from the actual values.
All physical values and counters can be indicated
via a special menu at the Batching Master. These
values are also shown via the Modbus interface.
Presentation Batching Master V08 © 2016 IBS BatchControl GmbH Page 16
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Loading station with Optimass 7300C in the hazardous area
Presentation Batching Master V08 © 2016 IBS BatchControl GmbH Page 17
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Custody transfer loading system with Optimass 7300C in the safe area
Optimass 7300C-CT Batching Master 110
4-20 mA
output
„density“
Pulse
input 1
Batching valve
with position controller
+5
- 6
4-20 mA
input 1
+ 9
- 10
4-20 mA
output
+
-
+ 15
- 16
pulse
output 1
D
D-
C
C-
Power
supply
RS
48
5 M
od
bu
s
inte
rfa
ce
DC
S
24V DC
+31 -32
Digital
output 1Digital
output 2
Sta
rtin
g
the
pu
mp
Pulse
input 2
+7
- 8
pulse
output 2
B
B-
Power
supply
4-20 mA
input 2
+11 -12 +1 -2
24V DC
Interface converter
RS232/RS485
PCC 400 Printer
communication
controllerProtocol printer
Optional monitor,
mouse and keybord
RS232
RS
48
5
RS 485 Modbus Interface to
the next Batching Master
RS232
Modbus
interface1
+39 -41
Data+
Data-
Modbus
interface2
+42 -44
B A
Digital
Input1
+19 -20
Ov
erf
ill
pro
tec
tio
n
Digital
Input2
+21 -22
Re
lea
se
DC
S
+29 -30
24V DC 24V DC
K1 K2
0V DC
K1 K2
Sw
itc
hin
g a
n
On
/Off
va
lve
Temperature
sensor, 2-wire
+ -
Presentation Batching Master V08 © 2016 IBS BatchControl GmbH Page 18
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Printing solutions and batch data storage system PCC400
- Custody transfer
proofed
- Storage and print out of
batch reports
- Storage and print out of
log files (alarm lists)
- Connection to the local
Ethernet
Data storage:
- Data base with all batch information
and export function into CSV files.
- PDF copy of the batch protocols on:
- an external USB stick or drive
- a storage path of the PCC 400
Optional:
- connection to external data bases
- Information input by the user before
the start via the terminal function
- Product way selection, controlled
by digital Modbus modules
PCC 400
local Ethernet
Batching Master Batching Master
Alarm printer
Report printer
Maintanance PC workstation Ext. data base
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Communication to an order management software via MYSQL:
- Information exchange between the order management software (TAS) and the
loading system in the field.
- Customers TAS software writes open loading orders into the MySQL table “loadings”.
- The operator enters an order number at the loading station as “Access control” and
the PCC 400 checks if this order is available and valid for the loading station.
- Important loading information will be shown in the field and the batch can be started.
- At the end of the batch the loading results will be written into the table “loadings”
Operation at the
batch controllers:
MySQL table “orders”:
- Order number
- Customer name
- Product name
- Status of the order
0 = order open
2 = order completed
MySQL table “loadings”, written by the PCC 400:
- Order number
- Customer name
- Product name
- TAG number
- Batch number
- Batch start and end time
Presentation Batching Master V08 © 2016 IBS BatchControl GmbH Page 20
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Flow computer Pipeline Master 110i/210i
For using at flow metering skids in pipelines or at continuous flow measuring
systems in chemical parks between two companies.
Flow conversion functions available for the calculation to standard volume
flow at 15°C out of the actual flow rate, temperature, pressure and density,
based on the following formulas:
- API 2540 tables A-C for crude oil, refined
and special products in metric units
- Linear correction
6 counter blocks are available with:
- mass, volume, standard volume
- in positive and reverse direction
- failure counters for all values
The PCC 400 is able to store the
counted values in files and to print
them via a connected printer.
Presentation Batching Master V08 © 2016 IBS BatchControl GmbH Page 21
Printer
Temperature
Printer Communication
Controller PCC 400RS 485 Modbus
Pipeline
Master 210
Pressure
Flow Rate / Density
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Non-Ex batch controller BC 20 for simple applications
Options:
- 4-20 mA valve output with ramp functions
- PID flow controller for the 4-20 mA output
- RS 485 Modbus interface
Features:
- Back light for the LCD
- Intelligent overrun correction
- Dimensions: 96 x 96 x 120 mm
BC 20-DC
PS = 24 VDC
BC 20-AC
PS = 100-240 VAC
LC-Display
with 2 x 16 caracters
Numeric key path
Batch
Controller
BC 20
24 VDC100-
240 VAC
Power Supply BC 20-DC
24 VDC, 250 mA
Power supply BC 20-AC
100-240 VAC, 47 – 63 Hz
22
PE
23
+24V
24
0V
22
PE
23
L1
24
N
Fuse
400 mA
Fuse
2 A
1 +
2 -
3 +
4 -U
5 +
6 -U
7 +
8 -U
11 +
12 +
13 +
14 -
Pulse input
NAMUR-
contacts
Passive
contacts
DI 1
DI 2
DI 3
Analog input 1
4-20 mA
Analog input 2
4-20 mA
Analog input 3
4-20 mA
Dig
ita
l in
pu
ts 1
-3
U
IP
4-20 mA output
Batching valve
op
tio
na
l
Relay-
output 1
I max = 2 A
19
20
21RS485 A-
B+ RS 485
Modbus-
interface op
tio
na
l
28
29
30
NO
NC
25
26
27
NO
NC
17
18
+
-
15
16
+
-
9+
10-
Optocouppler
output 1
I max = 50 mA
Optocouppler
output 2
I max = 50 mA
Relay-
output 2
I max = 2 A
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Power supply and interface modules
PSC 300i-1:
- One Exi power supply (U=24V, I=50mA)
for the PS1 of the Batching Master 110i/210i
PSC 320i-1:
- One Exi power supply (U=6V, I=100mA)
For the PS2 of the Batching Master 110i/210i
(required for the optional back light of the LCD)
PSC 330i-2:
- One Exi power supply (U=24V, I=50mA)
for the PS1 of the Batching Master 110i/210i
- One Exi power supply (U=6V, I=100mA)
For the PS2 of the Batching Master 110i/210i
(required for the optional back light of the LCD)
IPC 300i:
- One Exi power supply (U=24V, I=50mA)
for the PS1 of the Batching Master 110i/210i
- Interface barrier (MODBUS Protocol):
- Exi TTY interface to the Batching Master 110i/210i
- RS 485 interface at the safe area side
Presentation Batching Master V08 © 2016 IBS BatchControl GmbH Page 23
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Visualization of the loading:
Software system for Terminal Automatisation (TAS):
- Customer data base with delivery addresses
- Forwarder and truck data base
- Order management and a simple
creation of loading orders
- Visualization of the loading process
- Printout of delivery papers and statistics
- Direct loading without order
Options:
- Data exchange to SAP R/3 (optional)
- Access authorization via card readers
- OPC-Server for the connection to supervisory systems
- User access management and audit trail
- Multi user systems with client- / server architecture
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Trucks
Forwarders
Customers
Products
Order management:
Communication to the user via the
terminal function of the Batching Master:
Software system for visualization and order management
Data bases:
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Order code for the Batching Master 110i/210i:
120-0110 Batching Master 110i, ATEX, IP65 field housing
120-0120 Batching Master 110, non-Ex, IP65 field housing
120-0130 Batching Master 210i, ATEX, panel mount housing
120-0140 Batching Master 210, non-Ex, panel mount housing
120-0145 Back light for the LCD (an additional Exi power supply is required)
120-0150 Modbus interface (the interface and power supply module IPC 300i is required)
120-0160 Terminal function, the price includes the option „Modbus interface“
120-0165 Custody transfer version, the price includes the option „Modbus interface“
120-0170 PID controller function
120-0175 Flow conversion function between mass, volume and standard volume
120-0180 Special function „Automatic filling or empting of the measuring system“
120-0191 Selection of three product ways via the function keys F1-F3
120-0200 Emergency stop switch as a key switch
Exi interface and power supply modules:
A-120-0210 PSC 300i-1, power supply module, 1-channel
A-120-0210 PSC 330i-2, power supply module, 2-channel
A-120-0220 IPC 300i, interface and power supply module
Presentation Batching Master V08 © 2016 IBS BatchControl GmbH Page 26
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Some of our Main Clients:
3M, France, Germany
Abbot, USA, Germany
Air Liquide, France, Germany,
Aker Kvaerner, The Netherlands
Akzo Nobel, China, The Netherlands, Germany
Arkema, France, Germany
Astra Zeneca, England
BASF, Belgium, Malaysia, Mexico, China, Germany
Bayer, Malaysia, Spain, Vietnam, Germany
Basell, Germany
British American Tobacco, Germany
Butagaz, France
Clariant, China, Greece, Switzerland, Germany
Ciba, Italy, France, Switzerland, Germany
Christ Water Technology, Germany
Cognis, Germany
Degussa, Belgium, Germany
Dupont, Germany
DSM, The Netherlands, Austria, Germany
Endress+Hauser, worldwide
Emerson, worldwide
Exxon, France, The Netherlands
GlaxoSmithKline, Great Britain, Italy
Kraus Global, Kanada, Korea
KANEX, Russia, Ukraine
Krohne Messtechnik, worldwide
Lanxess, Germany
Linde, Germany
Lukoil, Ukraine
Lurgi, Germany
Merck, Germany
Novartis, Switzerland, Germany
Oiltanking, Belgium
Oval Asia, Singapore
Petroleos de Venezuela, Cuba
Petrobras, Brazil
Rhodia, France, Germany
Roche, Switzerland, Germany
Sanofi-Aventis, France, Germany
Sipchem, Saudi Arabia
Shell, Germany
Symrise, Germany
Tecnicas Reunidas, Spain
Total, France
Toyo Engineering, Japan
Uhde, China, Egypt, Ukraine, Germany
Vopak Banyan Terminals, Singapore
Wacker Chemie, China, India, Germany
Presentation Batching Master V08 © 2016 IBS BatchControl GmbH Page 27
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Presentation Batching Master V08 © 2016 IBS BatchControl GmbH Page 28
Indicators PID Controllers
Batch Controllers
Process Recorders Flow Computer
Exi Interfaces
IBS BatchControl GmbH
Im Sträßchen 2-4
53925 Kall /Germany
Tel.: +49 2441 9199 801
www.ibs-batchcontrol.de